Component Location Schematic Location
Machine Location
Schematic Location
Machine Location
Actuator - Engine Gov
A-9
1
Sender - Hydraulic Oil Temp
A-5
11
Alarm - Travel
G-9
2
Sensor - Engine Speed
B-8
Alternator
C-8
3
Sensor-Fuel Level
F-8
D
H-8, l-8
Breaker - Alternator
Wire Number
SENR1688 December 1996
Wire Description
Wire Color
Wire Number
Description
Wire Color
Description Accessory Circuits Cont
Power Distribution Circuits 101
RD
Bat (+)
576
PK
Wiper - Aux
103
RD
Aux Ckt
578
BU
Washer - Aux
105
RD
Key Sw
590
GY
Wiper Sw to Intermittent Module
6
107
RD
Eng Shutdown
592
BU
DC/DC Converter Power Output
A-5
12
108
BU
Aux Ckt
A513
RD
DC/DC Converter Memory Output
Sensor - Pump Discharge Press
B-8
13
109
RD
Alt Output (+) Term
A571
PU
Aux Ckt 1
4
Sensor - Sun Load
F-1
E
111
RD
Aux Ckt
A572
PK
Aux Ckt 2
112
PU
Main Power Rly Output
A579
OR
Wiper Motor (+)
I-8
D
Solenoid - A/C Clutch
C-9
14
113
OR
Opr Mon Panel B (+) Switched
A586
OR
Wiper Sw to Wiper Cant
Breaker - Main
I-8
D
Solenoid - Eng/Pump Control
A-7
15
114
RD
Warning Horn (Forward)
A588
GN
Safety Sal Relay to Sol
Control - Engine/Pump
F-2
C
Solenoid - Engine Shutdown
B-8
6
115
PK
Aux Ckt
C537
GN
A/C Photo Sensor (+) Sig
Controller - Wiper/Washer
E-1
E
Solenoid - Fine Swing
E-7
16
118
GY
Aux Ckt
C538
OR
A/C Photo Sensor (-) Sig
120
YL
Aux Ckt
Converter - Voltage
C-S
A
Solenoid - Grapple
E-7
16
123
WH
Aux Ckt
607
PK
Flood Lamps - FrontBoom
Diode - Main Relay
H-7
D
Solenoid - Hydraulic Lock
I-1
F
124
GN
A/C
615
YL
Cab Flood Lamp
I-4,5,6
B
Solenoid-Level Finish
A-7
15
129
BU
Aux Ckt
616
BU
140
BU
Aux Ckt
147
PU
Aux Ckt
763
BU
Torque Converter Sw
149
PU
Aux Ckt
786
GN
Eng Speed Cant
150
RD
Bat (+)
788
YL
Eng Speed (+)
151
GN
Aux Ckt
791
PK
Eng Speed Cont
152
BU
Aux Ckt
A755
PK
Throttle Sw #1
154
RD
Aux Ckt
A756
BU
Throttle Sw #2
168
RD
Aux Ckt
A757
GY
Throttle Sw #3
172
RD
Aux Ckt
A758
BR
Throttle Sw #4
177
RD
Main Brkr
A761
PU
Elec Pump Cont Gov Feedback
180
GN
Aux Ckt
A762
PU
Elec Pump Cant Eng Speed Ground
185
YL
Aux Ckt
A768
BU
Pump Control Valve #1 (+)
Component
Assembly - Terminal Block Batteries - 12VDC
Fuses
Component
17
B 18
2 10
4
20
D
9
A
5 8
3
14
F
C
E
7
24
Lighting Circuits
Flood Lamp Control Circuits
Ground - Cab
B-5
5
Solenoid - Rotate
D-7
16
Ground - Cab
E-1
E
Solenoid - Start Aid
H-9
17
Ground - Chassis
A-3
6
Solenoid - Swing Brake
E-7
16
Ground - Chassis
A-8
7
Solenoid - Travel Speed
A-7
15
Ground - Chassis
I-8
D
Solenoid - Trenching
A-7
15
Ground - Platform
G-2
F
Switch - Air Cleaner Flow
H-9
18
H-1
F
H-3
B
Ground - Relay Panel
H-7
D
Switch - Backup EPR Valve
E-5
C
Ground Strap - Chassis to Platform
I-6
8
Switch - Backup Governor
D-5
C
Ground Strap - Chassis to Riser
H-1
F
Switch - Boom Raise Pressure
D-7
C
189
RD
Aux Ckt
A769
GY
Pump Control Valve #2 (-)
Horn
A-2
7
Switch-Coolant Level
H-9
17
191
WH
Aux Ckt
A770
PK
Elec Pump Control Bypass Sw
Lighter
E-1
E
Switch - Disconnect
I-8
D
A771
PU
Float Sw
Meter - Service
F-1
E
Switch - Engine Oil Press
B-9
19
Monitor
F-1
E
Switch - Fine Swing Control
D-4
C
Motor - Starter
B-B
6
Switch - Grapple Close
F-2
C
Motor - Tilt
I-9
F
Switch - Grapple Open
I-1
B
Motor - Upper Washer
I-9
D
Switch - Horn
I-1
B
Motor - Upper Wiper
C-5
9
Switch - Hydraulic Oil Filter
A-5
11
C-6, I-3
A
Switch - Hydraulic Oil Level
A-5
11
Relay - Boom Lamp
I-7
D
Switch - Implement Pressure
D-7
16
Relay - Cab/Chassis Lamp
E-8
D
Switch - Key
F-2
C
Relay - Cab/Chassis Lamp
I-7
D
Switch - Neutral Start Limit
I-1
B
H-6
F
F-2
C
Relay - Grapple Open
H-5
F
Switch - Refrigerant Low Press
C-9
17
Relay - Horn
I-7
D
Switch - Rotate CCW
F-2
C
Relay - Hydraulic Lock Solenoid
I-7
D
Switch - Rotate CW
I-1
B
Relay - Main
G-7
D
Switch - Start Aid
D-5
C
Relay - Neutral Start
F-7
D
Switch - Start Aid Coolant Temp
B-9
10
Relay - Rotate CCW
H-6
F
Switch - Suction Line Shutoff Limit
A-6
11
Relay - Rotate CW
H-5
F
Switch - Throttle Position
E-3
C
Relay - Start
F-8
D
Switch - Travel Pressure
D-7
16
Relay - Timer
E-7
D
Switch Panel
F-2
C
Resistor - Backup
I-B
D
Unit - A/C, Heater
H-5
20
Sender - Coolant Temperature
B-9
10
Ground - Platform
Radio - 12VDC
Relay - Grapple Close
Switch - Aux Hydraulic Pressure
Switch - One Touch Low Idle
16
1
12
19
21
23
22
6
13
11 15
Ground Circuits
330B L Forest Swing Machine Electrical System 5
9 A 24
6DR1-UP
23
B
10 3
14
21 2
16
18 11
6
13
20 22 8
4
15
Main Chassis
F771
OR
Backup Sw
201
BK
Opr Mon Panel
F772
WH
Backup Sw
235
BK
Elec Pump Ctrl Gnd
F773
OR
Governor Accel
Basic Machine Circuits
F774
WH
Governor Decel
301
BU
Starter No. 1 Sol
J704
WH
Hyd Lock Sal Relay to Grapple and Rotate Sw
304
WH
Starter Rly No. 1 Output
J705
WH
Rotate CCW Relay to Sol
306
GN
Starter Rly Coil
J706
PU
Grapple Close Relay to Sol
307
OR
Key Sw to Neut Start Sw
J707
YL
Grapple Open Relay to Sol
308
YL
Main Power Rly Coil
J708
BR
Rotate CW Relay to Sol
310
PU
Start Aid Sw to Start Aid Sol
J709
GN
Cab/Chassis Lamp Relay
311
WH
Start Aid Sol to Temp Sw
J710
WH
Aux Ckt
320
OR
Horn Rly Coil to Sw
J711
GN
Aux Ckt
321
BR
Travel Alarm Lamp
J712
YL
Aux Ckt
322
GY
Warning Horn (Forward)
J713
BU
Aux Ckt
326
RD
Key Sw "C" Term
J714
BR
Aux Ckt
386
PK
Air Shutoff Enable
J715
OR
Aux Ckt
961
GN
Hyd Cont Sw
Monitoring_Circuits
F
D
BK
E
1
19
17
C
200
12 7
403
GN
Alternator (R) Term
K903
BR
Dual HP Relay to Controller
405
GY
Opr Mon Oil Press
K904
GN
Pump Discharge - Signal
412
BU
Opr Mon Cool Flow
K905
RD
Pump Discharge - (+) B
430
BU
Opr Mon Air Filter
K906
GN
Swing Brake Sol - Signal
487
OR
Hyd Oil Flow Sw
K907
BU
Swing Brake Sal - (+) B
491
PK
Hyd Oil Temp Sensor
K909
BU
Backup Sw - (+) B
492
GY
Coolant Temp Sensor
K911
PK
E/P Controller - RS485 (+)
495
GN
Fuel Level
K912
GN
E/P Controller - RS485 (-)
496
WH
Opr Mon Panel Hyd Oil Level
K915
GN
Fine Swing Sw - E/P Controller
C468
BU
Engine Oil Level
K997
BU
(+) V Sensor
L908
OR
Controller RS-232C TX
Accessory Circuits
Machine locations are repeated for components located close together.
501
GN
Wiper - Front
L909
BU
Controller RS-232C RX
506
PU
Washer - Front
L968
OR
Elec Pump Control PS Valve (-)
508
PU
Radio Speaker - Left
L969
WH
Elec Pump Control PS Valve (+)
A Located in operator’s compartment.
D = Located on or near relay panel.
B = Located in operator’s left console area.
E = Located in dash area.
509
WH
Radio Speaker - Left (Common)
L970
GY
Elec Pump Control to Switch Return
C = Located in operator’s right console area.
F = Located in Cab Riser.
511
BR
Radio Speaker - Right
L971
GN
Elec Pump Control to Travel Pressure Sw
512
GN
Radio Speaker - Right (Common)
L972
BU
Low Idle Sw
513
OR
A/C Compressor/Refrigerant Press Sw
L973
GN
Fine Swing Cont Relay to Sol Valve
519
PK
Thermostat to Refrigerant Press Sw
L974
GN
Elec Pump Cant Boom Raise Press Sw
546
BU
Aux Hyd - Rotate CW
L975
PK
Start Aid Cant Lamp 1 Output
547
OR
Aux Hyd - Rotate CCW
L977
YL
Trenching Sol
548
GY
Aux Hyd - Open
L978
GY
Level Finish Sol
549
PK
Aux Hyd - Close
Machine Harness Connector and Component Locations
Printed in U.S.A.
© 1996 Caterpillar All Rights Reserved
Part No. 3E-6449 3E-6455 106-0179 106-0180 106-0181
Function
Off Machine Switch Specification
Connector Location
Actuate
Deactuate
Contact Position
38.0 ± 3.0°C (100.4 ± 5.4°F)
27 °C MIN (80.6 °F MIN)
Normally Closed
90 ± 21 kPa (13 ± 3.0 psi)
70 ± 21 kPa (10 ± 3.0 psi)
A-B, Normally Open A-C, Normally Closed
Implement Pressure Travel Pressure
1225.00 ± 98.00 kPa (177.67 ± 14.21 psi)
882.00 kPa MIN (127.92 psi MIN)
Normally Open
Boom Raise Pressure
2646.00 ± 196.00 kPa (383.77 ± 28.43 psi)
2156.00 ± 196.00 kPa (312.70 ± 28.43 psi)
Normally Open
490.00 ± 49.00 kPa (71.07 ± 7.11 psi)
290.00 kPa MIN (42.06 psi MIN)
Normally Open
Start Aid Coolant Temperature Engine Oil Pressure
Hydraulic Pressure
275 to 1750 kPa ¹ 114-5333 A/C High/Low Pressure Normally Open ² (40 to 255 psi) ¹ A hysteresis band exists: with increasing pressure the closed condition can be maintained up to 2800 kPa (405 psi), with decreasing pressure the closed condition can be maintained down to 170 kPa (25psi). ² Contact postion at the contacts of the harness connector.
Real Time Error Codes Code
Description of Problems
Schematic Location
Machine Location
CONN 1
A-9
21
CONN 2
F-9
D
CONN 3
F-9
D
CONN 4
G-9
D
CONN 5
G-9
D
CONN 6
G-8
D
CONN 7
G-8
D
CONN 8
G-8
D
CONN 9
F-8
D
CONN 10
C-6
5
CONN 11
C-5
5
CONN 12
C-5
F
CONN 13
C-5
F
CONN 14
F-5
C
CONN 15
F-5
C
CONN 16
F-5
C
CONN 17
F-5
C
CONN 18
F-4
C
CONN 19
F-4
C
CONN 20
F-4
C
Alternator: (100-5047)
SENR2082
CONN 21
F-4
C
CONN 22
H-5
B
Engine/Pump Control
SENR9291
CONN 23
H-5
B
SENR9292
CONN 24
H-5
B
CONN 25
H-4
B
CONN 26
H-4
B
Starting And Charging Starting Motor: (6V-0512) Consist: 6V-0512 Starting Motor: (6V-5227) Consist: 6V-5538
CONN 27
H-4
B
CONN 28
H-3
B
CONN 29
H-3
B
CONN 30
C-3
F
CONN 31
B-3
7
CONN 32
A-3
22
CONN 33
B-2
23
CONN 34 Service Connector
D-2
C
CONN 35
B-2
24
CONN 36
G-5
F
CONN 37
G-5
F
CONN 38
G-8
F
CONN 39
G-8
F
CONN 40
G-8
F
CONN 41
F-9
F
CONN 42
F-9
F
CONN 43
G-9
F
CONN 44
G-9
F
CONN 45
G-9
D
CONN 46
H-9
F
Connector Number
A
Pressure Symbol
Related Electrical Service Manuals Title
Form Number
1304
Air filter is clogged.
1305
Battery voltage is not normal.
2201
Governor actuator feedback sensor circuit is open or shorted battery voltage.
2202
Governor actuator feedback sensor circuit is shorted to body ground.
2301
Governor actuator feedback signal is not stable.
2302
Governor actuator feedback signal deviates.
2303
Governor actuator does not move.
2304
Calibration data error.
3201
Monitor RAM is not normal.
4101
Electric power supply to the controller is too much (43 volts).
4102
Over-current in proportional reducing valve.
4103
Proportional reducing valve circuit is open.
4105
Over-current in digital output (trenching solenoid).
4106
Over-current in digital output (fine control solenoid).
4107
Over-current in digital output (travel speed change solenoid).
4108
Over-current in digital output (travel alarm).
410A
Over-current in digital output (swing break solenoid).
4201
Engine speed is not normal.
4202
Engine coolant temperature sensor is shorted to body ground.
4203
Hydraulic oil temperature sensor is shorted to body ground.
4204
PWM sensor of pump delivery pressure is shorted to body ground.
4207
PWM sensor of pump delivery pressure is open in circuit.
420A
Fuel sensor is shorted to body ground.
420B
Fuel sensor is open or shorted to battery voltage.
420C
Electric power supply is too low (below 23 volts).
420D
Electric power supply is too high (above 32 volts).
102-8017
Resistor - Backup
52.0 ± 2.6
420E
Engine speed dial is not one of the specified 10.
134-3998
Solenoid - A/C Clutch
17.6 ± 0.6
4301
Data mismatch 1 between alternator and speed sensor (alternator is abnormal).
111-9916
Solenoid - Engine/Pump Control
4302
Data mismatch 2 between alternator and speed sensor (speed sensor is abnormal).
A202
Monitor takes too much time to respond to controller’s signal.
A203
Communication is abnormal in controller.
Component Description
Solenoid - Engine Shutdown
3E-9205
Solenoid - Grapple
121-1491 121-1490 3E-6332 ¹ At room temperature unless otherwise noted.
Hydraulic Lock Solenoid - Swing Brake Travel Speed Level Finish Solenoid Trenching Solenoid - Start Aid
Normally open switch that will close with an increase of a specific condition (temp-press-etc.).
Component Part Number
Single Wire Connector C
Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition.
A
A 325-PK-14
Pin
AA 1
9X-1123 325-PK-14
Wire Color
Socket
2
FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch.
No circle indicates that the wire cannot be disconnected from the component.
Resistance (Ohms)¹
11.7 ± 1 .2 Start (Latch) Coil - 1.55 ± 0.15 Stop (Unlatch) Coil - 10.3 ± 1.03 24.9
This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine.
Wire Gauge
Electrical Schematic Symbols And Definitions
The circle indicates that the component has screw terminals and a wire can be disconnected from it.
This indicates that the component has a wire connected to it that is connected to ground.
200-BK-14
Circuit Number Identification
Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition.
CONN 47 H-9 F The connectors shown in this chart are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Chart.
Resistor, Sender and Solenoid Specifications
Wire, Cable, or Harness Assembly Identification
Normally closed switch that will open with an increase of a specific condition.
Hydraulic oil temperature is too high.
3E-7985
2
Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets.
SENR4975
1303
Monitor communication is not normal.
Flow Symbol
SENR3860
Engine coolant temperature is too high.
Engine stalls.
Level Symbol
Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins.
Pin or Socket Number
1302
4303
Temperature Symbol
1 2
1 2
Receptacle
Plug
T
Engine oil pressure is too low.
A201
AA 1
1301
Part No.
Harness And Wire Electrical Schematic Symbols
Electrical Schematic Symbols And Definitions
T
SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work.
32.0 ± 3.2 32.0 ± 3.2 6.0
MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches.